Polyphase transverse and/or commutated flux systems

ABSTRACT

Disclosed are single- and poly-phase transverse and/or commutated flux machines and components thereof, and methods of making and using the same. Exemplary devices, including polyphase devices, may variously be configured with an interior rotor and/or an interior stator. Other exemplary devices, including polyphase devices, may be configured in a slim, stacked, and/or nested configuration. Via use of such polyphase configurations, transverse and/or commutated flux machines can achieve improved performance, efficiency, and/or be sized or otherwise configured for various applications.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 12/948,925 filed onNov. 18, 2010, now U.S Patent Application Publication No. 2011/0062723entitled “POLYPHASE TRANSVERSE AND/OR COMMUTATED FLUX SYSTEMS”.

U.S. Ser. No. 12/948,925 is a divisional of U.S. Ser. No. 12/611,737filed on Nov. 3, 2009, now U.S. Pat. No. 7,868,508, entitled “POLYPHASETRANSVERSE AND/OR COMMUTATED FLUX SYSTEMS”.

U.S. Ser. No. 12/611,737 is a non-provisional of U.S. Provisional No.61/110,874 filed on Nov. 3, 2008 and entitled “ELECTRICAL OUTPUTGENERATING AND DRIVEN ELECTRICAL DEVICES USING COMMUTATED FLUX ANDMETHODS OF MAKING AND USE THEREOF INCLUDING DEVICES WITH TRUNCATEDSTATOR PORTIONS.”

U.S. Ser. No. 12/611,737 is also a non-provisional of U.S. ProvisionalNo. 61/110,879 filed on Nov. 3, 2008 and entitled “ELECTRICAL OUTPUTGENERATING AND DRIVEN ELECTRICAL DEVICES USING COMMUTATED FLUX ANDMETHODS OF MAKING AND USE THEREOF.”

U.S. Ser. No. 12/611,737 is also a non-provisional of U.S. ProvisionalNo. 61/110,884 filed on Nov. 3, 2008 and entitled “METHODS OF MACHININGAND USING AMORPHOUS METALS OR OTHER MAGNETICALLY CONDUCTIVE MATERIALSINCLUDING TAPE WOUND TORROID MATERIAL FOR VARIOUS ELECTROMAGNETICAPPLICATIONS.”

U.S. Ser. No. 12/611,737 is also a non-provisional of U.S. ProvisionalNo. 61/110,889 filed on Nov. 3, 2008 and entitled “MULTI-PHASEELECTRICAL OUTPUT GENERATING AND DRIVEN ELECTRICAL DEVICES WITH TAPEWOUND CORE LAMINATE ROTOR OR STATOR ELEMENTS, AND METHODS OF MAKING ANDUSE THEREOF.”

U.S. Ser. No. 12/611,737 is also a non-provisional of U.S. ProvisionalNo. 61/114,881 filed on Nov. 14, 2008 and entitled “ELECTRICAL OUTPUTGENERATING AND DRIVEN ELECTRICAL DEVICES USING COMMUTATED FLUX ANDMETHODS OF MAKING AND USE THEREOF.”

U.S. Ser. No. 12/611,737 is also a non-provisional of U.S. ProvisionalNo. 61/168,447 filed on Apr. 10, 2009 and entitled “MULTI-PHASEELECTRICAL OUTPUT GENERATING AND DRIVEN ELECTRICAL DEVICES, AND METHODSOF MAKING AND USING THE SAME.” The entire contents of all of theforegoing applications are hereby incorporated by reference.

TECHNICAL FIELD

The present disclosure relates to electrical systems, and in particularto transverse flux machines and commutated flux machines.

BACKGROUND

Motors and alternators are typically designed for high efficiency, highpower density, and low cost. High power density in a motor or alternatormay be achieved by operating at high rotational speed and therefore highelectrical frequency. However, many applications require lowerrotational speeds. A common solution to this is to use a gear reduction.Gear reduction reduces efficiency, adds complexity, adds weight, andadds space requirements. Additionally, gear reduction increases systemcosts and increases mechanical failure rates.

Additionally, if a high rotational speed is not desired, and gearreduction is undesirable, then a motor or alternator typically must havea large number of poles to provide a higher electrical frequency at alower rotational speed. However, there is often a practical limit to thenumber of poles a particular motor or alternator can have, for exampledue to space limitations. Once the practical limit is reached, in orderto achieve a desired power level the motor or alternator must berelatively large, and thus have a corresponding lower power density.

Moreover, existing multipole windings for alternators and electricmotors typically require winding geometry and often complex windingmachines in order to meet size and/or power needs. As the number ofpoles increases, the winding problem is typically made worse.Additionally, as pole count increases, coil losses also increase (forexample, due to resistive effects in the copper wire or other materialcomprising the coil). However, greater numbers of poles have certainadvantages, for example allowing a higher voltage constant per turn,providing higher torque density, and producing voltage at a higherfrequency.

Most commonly, electric motors are of a radial flux type. To a farlesser extent, some electric motors are implemented as transverse fluxmachines and/or commutated flux machines. It is desirable to developimproved electric motor and/or alternator performance and/orconfigurability. In particular, improved transverse flux machines and/orcommutated flux machines are desirable. Moreover, transverse fluxmachines and/or commutated flux machines configured to accommodatemulti-phase input and/or produce multi-phase output are desirable.

SUMMARY

This disclosure relates to transverse and/or commutated flux machines.In an exemplary embodiment, an electrical machine comprises a statorcomprising a set of flux conductors, and a conductive coil extendingonly partway around the electrical machine. The set of flux conductorsengage over 90% of the length of the conductive coil. The electricalmachine is at least one of a transverse flux machine or a commutatedflux machine.

In another exemplary embodiment, a hub motor for an electric vehiclecomprises a stator comprising a set of flux conductors, and a conductivecoil extending only partway around the electrical machine. The set offlux conductors engage over 90% of the length of the conductive coil.The hub motor is at least one of a transverse flux machine or acommutated flux machine.

In another exemplary embodiment, a motor for an electric vehiclecomprises a rotor having a first side and a second side separated by arotational plane of the rotor, a first set of flux conductors engagingthe first side, a second set of flux conductors engaging the secondside, and a conductive coil at least partially enclosed by the first setof flux conductors and the second set of flux conductors. The motor isat least one of a transverse flux machine or a commutated flux machine.

In another exemplary embodiment, a method of propelling a vehiclecomprises coupling an electrical machine to a hub of a vehicle in adirect drive configuration, and energizing a conductive coil of theelectrical machine to impart a rotational force to the hub. Theelectrical machine is at least one of a transverse flux machine or acommutated flux machine.

The contents of this summary section are provided only as a simplifiedintroduction to the disclosure, and are not intended to be used to limitthe scope of the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

With reference to the following description, appended claims, andaccompanying drawings:

FIG. 1A illustrates an exemplary transverse flux machine in accordancewith an exemplary embodiment;

FIG. 1B illustrates an exemplary commutated flux machine in accordancewith an exemplary embodiment;

FIG. 2A illustrates an exemplary axial gap configuration in accordancewith an exemplary embodiment;

FIG. 2B illustrates an exemplary radial gap configuration in accordancewith an exemplary embodiment;

FIG. 3A illustrates an exemplary cavity engaged configuration inaccordance with an exemplary embodiment;

FIG. 3B illustrates an exemplary face engaged configuration inaccordance with an exemplary embodiment;

FIG. 3C illustrates an exemplary face engaged transverse fluxconfiguration in accordance with an exemplary embodiment;

FIG. 4 illustrates electric motor efficiency curves in accordance withan exemplary embodiment;

FIG. 5A illustrates a cross-section of an exemplary single-phasestator/rotor assembly in accordance with an exemplary embodiment;

FIG. 5B illustrates a cross-section of an exemplary three-phaseconfiguration based on the single-phase configuration of FIG. 5A inaccordance with an exemplary embodiment;

FIG. 5C illustrates an exemplary three-phase rotor configuration inaccordance with an exemplary embodiment;

FIG. 5D illustrates, in close-up view, exemplary magnetic and fluxconcentrating portions of a rotor illustrated in FIG. 5C in accordancewith an exemplary embodiment;

FIG. 6A illustrates an exemplary polyphase device having an interiorstator in accordance with an exemplary embodiment;

FIG. 6B illustrates an exemplary polyphase device having an interiorstator in accordance with an exemplary embodiment;

FIG. 6C illustrates, in close-up view, a portion of the polyphase deviceof FIGS. 6A and 6B, wherein the inter-core flux conductor spacing hasbeen configured to create a 90° phase lag in accordance with anexemplary embodiment;

FIG. 7A illustrates an exemplary polyphase device having an interiorrotor in accordance with an exemplary embodiment;

FIG. 7B illustrates an exemplary polyphase device having an interiorrotor in accordance with an exemplary embodiment;

FIG. 7C illustrates, in close-up view, a portion of the polyphase deviceof FIGS. 7A and 7B in accordance with an exemplary embodiment;

FIG. 8A illustrates, in a perspective view, an exemplary polyphasedevice having a slim design in accordance with an exemplary embodiment;

FIG. 8B illustrates, in close-up view, a portion of the polyphase deviceof FIG. 8A in accordance with an exemplary embodiment;

FIG. 8C illustrates, in a face-on view, the exemplary polyphase deviceof FIGS. 8A and 8B in accordance with an exemplary embodiment;

FIG. 9A illustrates a polyphase device of FIGS. 8A-8C having a similarpolyphase device nested within in a phase-matched manner in accordancewith an exemplary embodiment;

FIG. 9B illustrates a polyphase device of FIGS. 8A-8C having a similarpolyphase device nested within in a phase-staggered manner in accordancewith an exemplary embodiment; and

FIG. 10 illustrates, in cross-sectional view, an exemplary polyphasedevice configured for use in a vehicle in accordance with an exemplaryembodiment.

DETAILED DESCRIPTION

The following description is of various exemplary embodiments only, andis not intended to limit the scope, applicability or configuration ofthe present disclosure in any way. Rather, the following description isintended to provide a convenient illustration for implementing variousembodiments including the best mode. As will become apparent, variouschanges may be made in the function and arrangement of the elementsdescribed in these embodiments without departing from the scope of theappended claims.

For the sake of brevity, conventional techniques for electrical systemconstruction, management, operation, measurement, optimization, and/orcontrol, as well as conventional techniques for magnetic fluxutilization, concentration, control, and/or management, may not bedescribed in detail herein. Furthermore, the connecting lines shown invarious figures contained herein are intended to represent exemplaryfunctional relationships and/or physical couplings between variouselements. It should be noted that many alternative or additionalfunctional relationships or physical connections may be present in apractical electrical system, for example an AC synchronous electricmotor.

Prior electric motors, for example conventional DC brushless motors,suffer from various deficiencies. For example, many electric motors areinefficient at various rotational speeds and/or loads, for example lowrotational speeds. Thus, the motor is typically operated within a narrowRPM range and/or load range of suitable efficiency. In theseconfigurations, gears or other mechanical approaches may be required inorder to obtain useful work from the motor.

Moreover, many electric motors have a low pole count. Because power is afunction of torque and RPM, such motors must often be operated at a highphysical RPM in order to achieve a desired power density and/orelectrical frequency. Moreover, a higher power density (for example, ahigher kilowatt output per kilogram of active electrical and magneticmotor mass) optionally is achieved by operating the motor at highrotational speed and therefore high electrical frequency. However, highelectrical frequency can result in high core losses and hence lowerefficiency. Moreover, high electrical frequency can result in increasedcost, increased mechanical complexity, and/or decreased reliability.Additionally, high electrical frequency and associated losses createheat that may require active cooling, and can limit the operationalrange of the motor. Heat can also degrade the life and reliability of ahigh frequency machine.

Still other electric motors contain large volumes of copper wire orother coil material. Due to the length of the coil windings, resistiveeffects in the coil lead to coil losses. For example, such lossesconvert a portion of electrical energy into heat, reducing efficiencyand potentially leading to thermal damage to and/or functionaldestruction of the motor.

Moreover, many prior electric motors offered low torque densities. Asused herein, “torque density” refers to Newton-meters produced perkilogram of active electrical and magnetic materials. For example, manyprior electric motors are configured with a torque density from about0.5 Newton-meters per kilogram to about 3 Newton-meters per kilogram.Thus, a certain electric motor with a torque density of 1 Newton-meterper kilogram providing, for example, 10 total Newton-meters of torquemay be quite heavy, for example in excess of 10 kilograms of activeelectrical and magnetic materials. Similarly, another electric motorwith a torque density of 2 Newton-meters per kilogram providing, forexample, 100 total Newton-meters of torque may also be quite heavy, forexample in excess of 50 kilograms of active electrical and magneticmaterials. As can be appreciated, the total weight of these electricmotors, for example including weight of frame components, housings, andthe like, may be significantly higher. Moreover, such prior electricmotors are often quite bulky as a result of the large motor mass. Often,a motor of sufficient torque and/or power for a particular applicationis difficult or even impossible to fit in the available area.

Even prior transverse flux machines have been unable to overcome thesedifficulties. For example, prior transverse flux machines have sufferedfrom significant flux leakage. Still others have offered torquedensities of only a few Newton-meters per kilogram of active electricaland magnetic materials. Moreover, various prior transverse flux machineshave been efficiently operable only within a comparatively narrow RPMand/or load range. Additionally, using prior transverse flux machines togenerate substantial output power often required spinning relativelymassive and complicated components (i.e., those involving permanentmagnets and/or relatively exotic, dense and/or expensive fluxconcentrating or conducting materials) at high rates of speed. Suchhigh-speed operation requires additional expensive and/or complicatedcomponents for support and/or system reliability. Moreover, many priortransverse flux machines are comparatively expensive and/or difficult tomanufacture, limiting their viability.

In contrast, various of these problems can be solved by utilizingtransverse flux machines configured in accordance with principles of thepresent disclosure. As used herein, a “transverse flux machine” and/or“commutated flux machine” may be any electrical machine wherein magneticflux paths have sections where the flux is generally transverse to arotational plane of the machine. In an exemplary embodiment, when amagnet and/or flux concentrating components are on a rotor and/or aremoved as the machine operates, the electrical machine may be a pure“transverse” flux machine. In another exemplary embodiment, when amagnet and/or flux concentrating components are on a stator and/or areheld stationary as the machine operates, the electrical machine may be apure “commutated” flux machine. As is readily apparent, in certainconfigurations a “transverse flux machine” may be considered to be a“commutated flux machine” by fixing the rotor and moving the stator, andvice versa. Moreover, a coil may be fixed to a stator; alternatively, acoil may be fixed to a rotor.

Moreover, there is a spectrum of functionality and device designsbridging the gap between a commutated flux machine and a transverse fluxmachine. Certain designs may rightly fall between these two categories,or be considered to belong to both simultaneously. Therefore, as will beapparent to one skilled in the art, in this disclosure a reference to a“transverse flux machine” may be equally applicable to a “commutatedflux machine” and vice versa.

Moreover, transverse flux machines and/or commutated flux machines maybe configured in multiple ways. For example, with reference to FIG. 2A,a commutated flux machine may be configured with a stator 210 generallyaligned with the rotational plane of a rotor 250. Such a configurationis referred to herein as “axial gap.” In another configuration, withreference to FIG. 2B, a commutated flux machine may be configured withstator 210 rotated about 90 degrees with respect to the rotational planeof rotor 250. Such a configuration is referred to herein as “radialgap.”

With reference now to FIG. 3A, a flux switch 352 in a commutated fluxmachine may engage a stator 310 by extending at least partially into acavity defined by stator 310. Such a configuration is referred to hereinas “cavity engaged.” Turning to FIG. 3B, flux switch 352 in a commutatedflux machine may engage stator 310 by closely approaching two terminalfaces of stator 310. Such a configuration is referred to herein as “faceengaged.” Similar engagement approaches may be followed in transverseflux machines and are referred to in a similar manner.

In general, a transverse flux machine and/or commutated flux machinecomprises a rotor, a stator, and a coil. A flux switch may be located onthe stator or the rotor. As used herein, a “flux switch” may be anycomponent, mechanism, or device configured to open and/or close amagnetic circuit. (i.e., a portion where the permeability issignificantly higher than air). A magnet may be located on the stator orthe rotor. A coil is at least partially enclosed by the stator or therotor. Optionally, flux concentrating portions may be included on thestator and/or the rotor. With momentary reference now to FIG. 1A, anexemplary transverse flux machine 100A may comprise a rotor 150A, astator 110A, and a coil 120A. In this exemplary embodiment, a magnet maybe located on rotor 150A. With momentary reference now to FIG. 1B, anexemplary commutated flux machine 100B may comprise a rotor 150B, astator 110B, and a coil 120B. In this exemplary embodiment, a magnet maybe located on stator 110B.

Moreover, a transverse flux machine and/or commutated flux machine maybe configured with any suitable components, structures, and/or elementsin order to provide desired electrical, magnetic, and/or physicalproperties. For example, a commutated flux machine having a continuous,thermally stable torque density in excess of 50 Newton-meters perkilogram may be achieved by utilizing a polyphase configuration. As usedherein, “continuous, thermally stable torque density” refers to a torquedensity maintainable by a motor, without active cooling, duringcontinuous operation over a period of one hour or more. Moreover, ingeneral, a continuous, thermally stable torque density may be consideredto be a torque density maintainable by a motor for an extended durationof continuous operation, for example one hour or more, without thermalperformance degradation and/or damage.

Moreover, a transverse flux machine and/or commutated flux machine maybe configured to achieve low core losses. By utilizing materials havinghigh magnetic permeability, low coercivity, low hysteresis losses, loweddy current losses, and/or high electrical resistance, core losses maybe reduced. For example, silicon steel, powdered metals, plated powderedmetals, soft magnetic composites, amorphous metals, nanocrystallinecomposites, and/or the like may be utilized in rotors, stators,switches, and/or other flux conducting components of a transverse fluxmachine and/or commutated flux machine. Eddy currents, flux leakage, andother undesirable properties may thus be reduced.

A transverse flux machine and/or commutated flux machine may also beconfigured to achieve low core losses by varying the level of saturationin a flux conductor, such as in an alternating manner. For example, aflux conducting element in a stator may be configured such that a firstportion of the flux conducting element saturates at a first time duringoperation of the stator. Similarly, a second portion of the same fluxconducting element saturates at a second time during operation of thestator. In this manner, portions of the flux conducting element have alevel of magnetic flux density significantly below the saturationinduction from time to time, reducing core loss. For example,significant portions of the flux conducting element may have a level offlux density less than 25% of the saturation induction within the 50% ofthe time of its magnetic cycle. Moreover, any suitable flux densityvariations may be utilized.

Furthermore, a transverse flux machine and/or commutated flux machinemay be configured to achieve low coil losses. For example, in contrastto a conventional electric motor utilizing a mass of copper C in one ormore coils in order to achieve a desired output power P, a particulartransverse flux machine and/or commutated flux machine may utilize onlya small amount of copper C (for example, one-tenth as much copper C)while achieving the same output power P. Additionally, a transverse fluxmachine and/or commutated flux machine may be configured to utilize coilmaterial in an improved manner (for example, by reducing and/oreliminating “end turns” in the coil). In this manner, resistive losses,eddy current losses, thermal losses, and/or other coil losses associatedwith a given coil mass C may be reduced. Moreover, within a transverseflux machine and/or commutated flux machine, a coil may be configured,shaped, oriented, aligned, manufactured, and/or otherwise configured tofurther reduce losses for a given coil mass C.

Additionally, in accordance with principles of the present disclosure, atransverse flux machine and/or commutated flux machine may be configuredto achieve a higher voltage constant. In this manner, the number ofturns in the machine may be reduced, in connection with a higherfrequency. A corresponding reduction in coil mass and/or the number ofturns in the coil may thus be achieved.

Yet further, in accordance with principles of the present disclosure, atransverse flux machine and/or commutated flux machine may be configuredto achieve a high flux switching frequency, for example a flux switchingfrequency in excess of 1000 Hz. Because flux is switched at a highfrequency, torque density may be increased.

With reference now to FIG. 4, a typical conventional electric motorefficiency curve 402 for a particular torque is illustrated. Revolutionsper minute (RPM) is illustrated on the X axis, and motor efficiency isillustrated on the Y axis. As illustrated, a conventional electric motortypically operates at a comparatively low efficiency at low RPM. Forthis conventional motor, efficiency increases and then peaks at aparticular RPM, and eventually falls off as RPM increases further. As aresult, many conventional electric motors are often desirably operatedwithin an RPM range near peak efficiency. For example, one particularprior art electric motor may have a maximum efficiency of about 90% atabout 3000 RPM, but the efficiency falls off dramatically at RPMs thatare not much higher or lower.

Gearboxes, transmissions, and other mechanical mechanisms are oftencoupled to an electric motor to achieve a desired output RPM or otheroutput condition. However, such mechanical components are often costly,bulky, heavy, and/or impose additional energy losses, for examplefrictional losses. Such mechanical components can reduce the overallefficiency of the motor/transmission system. For example, an electricmotor operating at about 90% efficiency coupled to a gearbox operatingat about 70% efficiency results in a motor/gearbox system having anoverall efficiency of about 63%. Moreover, a gearbox may be largerand/or weigh more or cost more than the conventional electric motoritself Gearboxes also reduce the overall reliability of the system.

In contrast, with continuing reference to FIG. 4 and in accordance withprinciples of the present disclosure, a transverse and/or commutatedflux machine efficiency curve 404 for a particular torque isillustrated. In accordance with principles of the present disclosure, atransverse and/or commutated flux machine may rapidly reach a desirableefficiency level (for example, 80% efficiency or higher) at an RPM lowerthan that of a conventional electric motor. Moreover, the transverseand/or commutated flux machine may maintain a desirable efficiency levelacross a larger RPM range than that of a conventional electric motor.Additionally, the efficiency of the transverse and/or commutated fluxmachine may fall off more slowly past peak efficiency RPM as compared toa conventional electric motor.

Furthermore, in accordance with principles of the present disclosure, atransverse and/or commutated flux machine may achieve a torque densityhigher than that of a conventional electric motor. For example, in anexemplary embodiment a transverse and/or commutated flux machine mayachieve a continuous, thermally stable torque density in excess of 100Newton-meters per kilogram.

Thus, in accordance with principles of the present disclosure, atransverse and/or commutated flux machine may desirably be employed invarious applications. For example, in an automotive application, atransverse and/or commutated flux machine may be utilized as a wheel hubmotor, as a direct driveline motor, and/or the like. Moreover, in anexemplary embodiment having a sufficiently wide operational RPM range,particularly at lower RPMs, a transverse and/or commutated flux machinemay be utilized in an automotive application without need for atransmission, gearbox, and/or similar mechanical components.

An exemplary electric or hybrid vehicle embodiment comprises atransverse flux motor for driving a wheel of the vehicle, wherein thevehicle does not comprise a transmission, gearbox, and/or similarmechanical component(s). In this exemplary embodiment, the electric orhybrid vehicle is significantly lighter than a similar vehicle thatcomprises a transmission-like mechanical component. The reduced weightmay facilitate an extended driving range as compared to a similarvehicle with a transmission like mechanical component. Alternatively,weight saved by elimination of the gearbox allows for utilization ofadditional batteries for extended range. Moreover, weight saved byelimination of the gearbox allows for additional structural material forimproved occupant safety. In general, a commutated flux machine having abroad RPM range of suitable efficiency may desirably be utilized in avariety of applications where a direct-drive configuration isadvantageous. For example, a commutated flux machine having anefficiency greater than 80% over an RPM range from only a few RPMs toabout 2000 RPMs may be desirably employed in an automobile.

Moreover, the exemplary transmissionless electric or hybrid vehicle mayhave a higher overall efficiency. Stated otherwise, the exemplaryvehicle may more efficiently utilize the power available in thebatteries due to the improved efficiency resulting from the absence of atransmission-like component between the motor and the wheel of thevehicle. This, too, is configured to extend driving range and/or reducethe need for batteries.

Additionally, the commutated flux machine is configured to have a hightorque density. In accordance with principles of the present disclosure,the high torque density commutated flux machine is also well suited foruse in various applications, for example automotive applications. Forexample, a conventional electric motor may have a torque density ofbetween about 0.5 to about 3 Newton-meters per kilogram. Additionaltechniques, for example active cooling, can enable a conventionalelectric motor to achieve a torque density of up to about 50Newton-meters per kilogram. However, such techniques typically addsignificant additional system mass, complexity, bulk, and/or cost.Additionally, such conventional electric motors configured to producecomparatively high amounts of torque, for example the Siemens 1FW6motor, are limited to comparatively low RPM operation, for exampleoperation below 250 RPMs.

In contrast, in accordance with principles of the present disclosure, anexemplary passively cooled transverse flux machine and/or commutatedflux machine may be configured with a continuous, thermally stabletorque density in excess of 50 Newton-meters per kilogram. As usedherein, “passively cooled” is generally understood to refer to systemswithout cooling components requiring power for operation, for examplewater pumps, oil pumps, cooling fans, and/or the like. Moreover, thisexemplary transverse flux machine and/or commutated flux machine may beconfigured with a compact diameter, for example a diameter less than 14inches. Another exemplary transverse flux machine and/or commutated fluxmachine may be configured with a continuous, thermally stable torquedensity in excess of 100 Newton-meters per kilogram and a diameter lessthan 20 inches. Accordingly, by utilizing various principles of thepresent disclosure, exemplary transverse flux machines and/or commutatedflux machines may be sized and/or otherwise configured and/or shaped ina manner suitable for mounting as a wheel hub motor in an electricvehicle, because the transverse flux machine and/or commutated fluxmachine is significantly lighter and/or more compact than a conventionalelectric motor. In this manner, the unsprung weight of the resultingwheel/motor assembly can be reduced. This can improve vehicle handlingand reduce the complexity and/or size of suspension components.

Further, in accordance with principles of the present disclosure, atransverse flux machine and/or commutated flux machine may desirably beutilized in an electromechanical system having a rotating portion, forexample a washing machine or other appliance. In one example, aconventional washing machine typically utilizes an electric motorcoupled to a belt drive to spin the washer drum. In contrast, atransverse flux machine and/or commutated flux machine may be axiallycoupled to the washer drum, providing a direct drive configuration andeliminating the belt drive element. Alternatively, a transverse fluxmachine and/or commutated flux machine, for example one comprising apartial stator, may be coupled to a rotor. The rotor may have a commonaxis as the washer drum. The rotor may also be coupled directly to thewasher drum and/or integrally formed therefrom. In this manner, atransverse flux machine and/or commutated flux machine may providerotational force for a washing machine or other similarelectromechanical structures and/or systems.

Moreover, in accordance with principles of the present disclosure, atransverse flux machine and/or commutated flux machine may desirably beutilized to provide mechanical output to relatively lightweight vehiclessuch as bicycles, scooters, motorcycles, quads, golf carts, or othervehicles. Additionally, a transverse flux machine and/or commutated fluxmachine may desirably be utilized in small engine applications, forexample portable generators, power tools, and other electricalequipment. A transverse flux machine and/or commutated flux machine maydesirably be utilized to provide mechanical output to propeller-drivendevices, for example boats, airplanes, and/or the like. A transverseflux machine and/or commutated flux machine may also desirably beutilized in various machine tools, for example rotating spindles, tablesconfigured to move large masses, and/or the like. In general, transverseflux machines and/or commutated flux machines may be utilized to provideelectrical and/or mechanical input and/or output to and/or from anysuitable devices.

In accordance with various exemplary embodiments, exemplary transverseflux and/or commutated flux machines are configured to accommodatepolyphase input and/or produce polyphase output. Polyphase input and/oroutput devices can have various advantages compared to single-phasedevices. For example, polyphase motors may not require externalcircuitry or other components in order to produce an initialing torque.Polyphase devices can also avoid pulsating and/or intermittency, forexample pulsating and/or intermittency caused when current produced by asingle phase device passes through the part of its cycle in which thecurrent has zero amplitude. Instead, polyphase devices can deliversubstantially constant power output over each period of an alternatingcurrent input, and vice versa.

Polyphase devices can be produced using layouts similar to single phaselayouts disclosed in various co-pending applications incorporated byreference herein. Polyphase devices can also be produced using layoutshaving single rotor/stator sets, or layouts having polyphase featuresthat differ from single phase rotor/stator layouts. Moreover, polyphasedevices can be produced in any suitable configurations, as desired.

Although exemplary embodiments shown herein generally have magnets on arotor portion and flux switches on a stator portion, it should be notedthat other variations may be made in accordance with aspects of thepresent disclosure. For example, flux switches may be mounted onto arotor portion, and a series of magnets may be mounted onto a statorportion. Alternatively, flux switches can be mounted onto a rotorportion and an electromagnet can be mounted onto a stator portion.Numerous other relationships between a stator portion and a rotorportion are also possible. For example, either a stator portion or arotor portion may be mounted as an exterior-most component. Moreover,magnets, flux concentrators, and/or flux switches may be arranged,configured, and/or coupled in order to conduct magnetic flux in such away as to either generate electrical output or to drive the rotor. Inaddition, flux switches, flux concentrators, coils, and/or magnets canbe mounted to either of a rotor portion or a stator portion.

In general, certain exemplary polyphase devices may be constructed bycombining, linking, and/or otherwise utilizing and/or including suitableelements of single-phase devices. In an exemplary embodiment and withreference now to FIG. 5A, a single phase device 500A comprises rotor550, a stator 510, and a coil 520. Single phase device 500A isillustrated here in cross section showing a transverse flux machine. Inthis exemplary embodiment, rotor 550 is cavity engaged with stator 510in an axial gap configuration. Stator 510 partially surrounds coil 520.

In an exemplary embodiment, stator 510 is held stationary and rotor 550rotates about an axis of rotation 551. It will be readily appreciatedthat in various other exemplary configurations, rotor 550 may be heldstationary, so as to act as a stator. In these embodiments, stator 510may be moved, so as to act as a rotor.

In various embodiments, rotor 550 comprises a stack of alternatingmagnet and flux concentrating portions.

With reference now to FIG. 5B, in various exemplary embodiments apolyphase design may be constructed by duplicating one or more portionsof a single-phase design. In an exemplary embodiment, polyphase device500B comprises three rotor portions 550A, 550B, and 500C placedconcentrically around a common axis of rotation

In various exemplary embodiments, polyphase device 500B comprises anysuitable number of rotors and/or stators, for example two rotors, fourrotors, five rotors, and so on. Moreover, rotor portions 550A, 550B, and550C can be capable of independent rotation. Alternatively, rotorsportions 550A, 550B, and 550C can be coupled to one another, such thatrotor portions 550A, 550B, and 550C rotate together.

In certain exemplary embodiments, rotor portions 550A, 550B, and 550Care very similar in design or even identical, as illustrated in FIG. 5B.In other exemplary embodiments, one or more of rotor portions 550A,550B, and 550C may be smaller than others. In yet other exemplaryembodiments, rotor portions 550A, 550B, and 550C differ from oneanother.

In various exemplary embodiments, a rotor portion 550 (e.g., one or moreof 550A, 550B, or 550C) has a cross sectional shape. For example, arotor portion 550 may have a wedge shape. Alternatively, the rotorportions 550 may comprise various other suitable shapes, for example anarrow-head shape, a circular cross sectional shape, a rectangularcross-sectional shape, and/or the like.

In various embodiments, rotor portions 550A, 550B, and 550C, whenassembled into an electrically driven device and/or electrical outputdevice, each comprise a stack of alternating magnet and fluxconcentrating portions.

In various exemplary embodiments, each rotor portion 550A, 550B, 550C ofpolyphase device 500B corresponds to a coil 520 a, 520B, and 520C,respectively. Coils 520A, 520B, and 520C are typically orientedcircumferentially about the center of polyphase device 500B. Generally,coils 520A, 520B, and 520C are fixed to the corresponding stator portionand thus do not rotate with rotor portions 550A, 550B, and 550C. Inaddition, stator portions 510A, 510B and 510C corresponding to eachrotor are occupy at least a portion of the space between coils 520A,520B, and 520C. In an exemplary embodiment, rotor portions 550A, 550B,and 550C rotate independently of stator portions 510A, 510B and 510C,which generally remain fixed.

Alternatively, rotor portions 550A, 550B, 550C can remain fixed so as tobe the stator portion. In these embodiments, coils 520A, 520B, and 520Cas well as stator portions 510A, 510B and 510C are rotated with respectto the rotor portions.

With reference now to FIG. 5C, in various exemplary embodiments, rotorportions 550A, 550B, and 550C of FIG. 5B are configured with a phase lagamong rotor portions 510A, 510B and 510C. Magnet portions 554A, 554B and554C are located on each of rotor portions 550A, 550B, and 550C,respectively. Moreover, multiple magnet portions 554A, 554B and 554C arelocated on each of rotor portions 550A, 550B, and 550C. For example,each rotor portion may comprise a pattern of alternating magnets andflux concentrating portions. With reference to FIG. 5D, for example,rotor 550 comprises a pattern of alternating magnets 554 and fluxconcentrating portions 552 and 556. This pattern may be repeated aboutthe circumference of a rotor portion 550 so as to at least partiallyform the shape of a rotor portion 550.

In an exemplary embodiment, each of the magnet portions 554 on each ofthe rotors 550 is located between two flux conducting portions. Forexample, a particular magnet 554 is located between flux conductingportion 552 and 556. In general, magnets 554 may be arranged such thatmagnet surfaces having a common polarity engage a common fluxconcentrating portion (see, e.g., FIG. 5D). Moreover, in variousexemplary embodiments a magnet portion 554 may be located adjacentadditional and/or fewer flux conducting portions, as desired.

With reference again to FIG. 5C, in various exemplary embodiments rotorportions 550A, 550B, and 550C are partially rotated with respect to oneanother. In this manner, a phase lag p is defined between rotor portions550A and 550B. Similarly, a phase lag p2 is defined between rotorportions 550B and 550C. Moreover, additional rotors 550 may be utilizedto create additional phase lags, as desired.

Rotor portions 550A, 550B and 550C may be fixed relative to one another.In this manner, phase lags p1 and p2 are maintained as rotor portions550A, 550B and 550C turn while in operation. Phase lags p1 and p2 causeeach of rotor portions 550A, 550B, and 550C to produce a different phaseof output. Moreover, rotor portions 550A, 550B, and 550C may also bemovable with respect to one another in order to vary one or more phaselags.

As will be appreciated by one skilled in the art, phase lags p1 and p2illustrated in FIG. 5C are merely representative. Numerous other phaselags and/or combinations of the same may be created in accordance withprinciples of the present disclosure. All such phase lags and/orresulting device input and/or output characteristics are considered tobe within the scope of the present disclosure.

In an exemplary embodiment, polyphase device 500B may be operated as anelectrical output device. In these configurations, each of rotorportions 550A, 550B, and 550C generates an alternating electrical output(for example, a substantially sinusoidal output) in corresponding coils520A, 520B, and 520C. The electrical output of each coil 520A, 520B, and520C has a phase that is shifted by a phase lag relative to each of theother coils 520A, 520B, and 520C (alternatively, advanced relative toeach of the other coils 520A, 520B, and 520C). In general, the number ofphase lags in polyphase device 500B may be up to one less than thenumber of rotor portions. For example, three rotor portions 550A, 550B,and 550C may be configured to create two phase lags. Three rotorportions 550A, 550B, and 550C may also be configured to create one phaselag (for example, if rotor portions 550B and 550C are aligned similarlywith respect to rotor portion 550A). Three rotor portions 550A, 550B,and 550C may also be configured to create no phase lag when all threerotor portions 550A, 550B, and 550C are aligned similarly to oneanother. In general, any suitable number of phase lags, and any suitablemagnitude of phase lags, may each be utilized, as desired.

For example, in various exemplary embodiments, in polyphase device 500B,the magnitude of each phase lag may be adjusted by adjusting therelative rotational alignment of each of the rotor portions 550.Polyphase device 500B may be operated as an electrical output device. Inthese configurations, phase outputs may be shifted evenly relative toeach other within each period of the alternating output. For example, ina three-phase arrangement, the phases can be shifted relative to eachother by one-third of the period. Alternatively, the phases can beshifted unevenly with respect to one another. For example, a secondphase may be shifted 30 degrees with respect to a first phase. A thirdphase may be shifted by 60 degrees with respect to the second phase (andconsequently, shifted by 90 degrees with respect to the first phase).Additional phases may similarly be shifted by any suitable value, asdesired.

In various exemplary embodiments, in polyphase device 500B each phaseoutput is produced by a different rotor portion 550A, 550B, and 550C andcorresponding stator 510A, 510B, and 510C and coil 520A, 520B, and 520C.In other exemplary embodiments, polyphase device 500B is configured witha single stator portion 510 divided into separate phases sharing one ormore rotors. In these exemplary embodiments, the number of components ofthe polyphase device may be reduced. For example, the polyphase devicemay produce and/or utilize more input/output phases than the number ofrotors comprising the polyphase device. Further, in these exemplaryembodiments the size the polyphase device may be reduced, for example byreducing a thickness of the polyphase device in at least a directionparallel to the axis of rotation of a rotor.

For example, with reference now to FIGS. 6A and 6B, a polyphase device600 may be configured with one or more interior stators. As used herein,an “interior stator” refers to a stator having a portion thereof and/orvarious components thereof disposed substantially between two or morerotors. In various exemplary embodiments, polyphase device 600 comprisesthree stators each comprising a plurality of flux conducting portions612 (shown as 612A, 612B, and 612C). Polyphase device 600 furthercomprises three coils 620A, 620B, 620C, and two rotors 650X, 650Y. Fluxconducting portions 612A, 612B, and 612C, and coils 620A, 620B, and 620Care located substantially between rotors 650X and 650Y.

Coils 620A, 620B, and 620C may each correspond to a different outputphase. In various exemplary embodiments, spacing between flux conductingportions 612 within stators 610 is configured to create one or morephase relationships, as discussed below. In addition, polyphase device600 may comprise any suitable number of coils 620, for example two coils620, four coils 620, ten coils 620, and/or the like. Accordingly,polyphase device 600 may be configured with a number of output phases upto the number of coils 620 and corresponding phase portions of one ormore stators and/or rotors. Additionally, multiple coils 620 may beconfigured to correspond to a similar phase.

Coils 620A, 620B, and 620C can comprise any suitable material configuredto conduct electrical current responsive to a changing magnetic field,for example copper wire windings. In various exemplary embodiments, oneor more coils 620 are wound from flat wire (i.e., wire having arectangular cross section, as opposed to a circular cross section).Moreover, any of the coils, output windings, electrical connectors,and/or the like contemplated by this disclosure and/or in relateddisclosures, as suitable, can be fabricated from flat wire. Flat wire ina coil 620 allows more efficient filling of available space withconductive material. In this manner, a higher packing density of wire inthe coil may be achieved. Efficiency gains from the increased packingdensity can outweigh potential disadvantages, for example the resultingincreased weight of a particular coil. Moreover, any suitable materialand/or shape of wire and/or coil may be used.

In various exemplary embodiments, with continued reference to FIG. 6B,each of the coils 620A, 620B, and 620C of polyphase device 600 comprisesa loop with a forward portion, 620AF, 620BF, 620CF, and a rear portion,620AR, 620BR, 620CR, respectively. Each of the forward and rear portionsof coils 620A, 620B, and 620C of the polyphase device 600 issubstantially surrounded by flux conducting portions 612 ofcorresponding stators such that magnetic flux can be conducted aroundcoils 620A, 620B, and 620C.

In various exemplary embodiments, coils 620A, 620B, and 620C extendalong a portion of a circumference of a circle. Coils 620A, 620B, and620C may extend any suitable portion of a circumference of a circle, forexample approximately one-third of the circumference. Coils 620A, 620B,and 620C may extend along portions having similar length. Moreover,coils 620A, 620B, and 620C may extend along portions having dissimilarlengths, as desired.

Moreover, forward portion 620AF may define a first arc, for example asemicircular arc, and rear portion 620AR may define a second arc, forexample a semicircular arc. The first and second arcs may have a commonradius from a common axis, for example a rotational axis of a transverseflux and/or commutated flux machine. Moreover, the first and second arcs(and/or forward portion 620AF and rear portion 620AR) may traverse asimilar angular portion of a transverse flux machine. For example, in anexemplary three-phase embodiment, approximately 0° to 120° of thetransverse flux machine is associated with a first coil (i.e. with afirst and second portion of the first coil), approximately 120° to 240°of the transverse flux machine is associated with a second coil and itsrespective first and second portions, and approximately 240° to 360° ofthe transverse flux machine is associated with a third coil and itsrespective first and second portions. Moreover, the first and secondarcs, (and/or forward portion 620AF and rear portion 620AR) may traverseoverlapping angular portions of a transverse flux machine. For example,forward portion 620AF may traverse approximately 0° to 120° of thetransverse flux machine, and rear portion may traverse approximately 5°to 115° of the transverse flux machine; thus, the angular portions areentirely overlapping. Additionally, the first and second arcs, (and/orforward portion 620AF and rear portion 620AR) may traverse partiallyoverlapping angular portions of a transverse flux machine. For example,forward portion 620AF may traverse approximately 0° to 120° of thetransverse flux machine, and rear portion 620AR may traverseapproximately 5° to 125° of the transverse flux machine; thus, theangular portions are partially overlapping.

Conduction of flux through the flux conducting portions 612 about eachof coils 620A, 620B, and 620C is able to produce an electrical output ineach of coils 620A, 620B, and 620C. In various exemplary embodiments,flux is conducted through flux conducting portions 612A such that fluxconducting portions 612A substantially surrounding forward portion 620AFare in phase with flux conducting portions 612A substantiallysurrounding rear portion 620AF. In this manner, forward portion 620AFand rear portion 620AR are in phase. Similar phase arrangements may befound in portions 620BF and 620CF, and 620BR and 620CR, respectively. Inother exemplary embodiments, a forward portion may be out of phase witha corresponding rear portion.

Moreover, in various exemplary embodiments, a coil, for example coil620A, may be oriented about a rotational axis of polyphase device 600such that current in forward portion 620AF flows in a direction ofrotation simultaneously with current in rear portion 620AR flowingopposite the direction of rotation. Stated another way, in variousembodiments, current within coil 620A may be considered to flow around asomewhat “racetrack”-shaped loop extending only a portion of the angulardistance around the rotational axis.

As will be readily appreciated, coils 620B and/or 620C may be shaped,sized, aligned, configured and/or may otherwise function and/or behavein a manner similar to coil 620A and portions thereof as describedabove.

In various exemplary embodiments, with continued reference to FIG. 6B,the flux conducting portions of polyphase device 600 can be C-shaped.Alternatively, the flux conducting portions can have one of a number ofother shapes, for example U-shapes, rectilinear shapes, ovular shapesand linear shapes, in either cross-section or perspective, as desired.These flux conducting portions may be formed in any suitable manner. Forexample, the flux conducting portions can be fashioned from tape-woundtorroid material, material including metallic glasses, laminated steel,powdered metal, or combinations of a number of these or other suitableflux conducting materials.

In an exemplary embodiment, with continued reference to FIG. 6B, theintra-coil flux conductor spacings S610A, S610B, and S610C (S610B andS610C not shown) (i.e., the spacings between adjacent flux conductingportions 612A, 612B, and 612C, respectively) are approximately uniformsize. In addition, the spacing between adjacent flux conducting portionswith respect to the forward portions 620AF, 620BF, and 620CF and rearportions 620AR, 620BR, and 620CR, of each of the coils are generallyabout the same size. However, the intra-coil flux conductor spacingsS610A, S610B, and S610C on either and/or both the forward portions620AF, 620BF, and 620CF and rear portions 620AR, 620BR, and 620CR ofeach of the coils can be other than approximately equal. For example,these flux conductor spacings may be varied in order to create differentfrequency outputs, or for other suitable purposes.

In contrast, with reference again to FIG. 6B, the inter-coil fluxconductor spacings SA-B, SB-C, and SC-A (SC-A not shown) (i.e., theon-center spacings between adjacent flux conducting portions on adjacentcoils 620A, 620B, and 620C), however, are generally unequal in size. Invarious exemplary embodiments, the inter-coil flux conductor spacingsvary in order to set a particular phase relationship among the phases ofthe electrical output generated in each of coils 620A, 620B, and 620C.These phase relationships among coils and their association with variouscomponents of the rotors will be discussed in more detail below.However, in certain cases, it may be advantageous to have one or more ofthe inter-core flux conductor spacings SA-B, SB-C, and SC-A beapproximately equal to another.

With reference now to FIG. 6C, a close-up view of a polyphase device 600is illustrated. In an exemplary embodiment, the two rotor portions 650X,650Y in polyphase device 600 are at least partially received within fluxconducting portions 612 comprising stators 610. Rotor portions 650X,650Y may be very similar and/or identical. Additionally, rotor portions650X, 650Y may have a similar construction to rotors used in singlephase devices. In various exemplary embodiments, rotor portions 650X,650Y are generally aligned with one another.

Alternatively, rotor portions 650X, 650Y can have substantialdifferences. For example, rotor portions 650X, 650Y may be at leastpartially rotated relative to one another. Stated another way, rotorportions 650X, 650Y may be unaligned. Rotor portions 650X, 650Y may alsohave different sized alternating magnet portions 654 and/or fluxconcentrators 652.

In various exemplary embodiments, alternating magnet portions 654 andflux concentrators 652 are similar in features and functions to thecorresponding regions 554 and 552/556, respectively, of rotor 550 asillustrated in FIG. 5D.

Moreover, in these embodiments rotor portions 650X, 650Y may besubstantially similar to the rotors 550 used in polyphase device 500B.For example, like the magnet portions 554 of a rotor 550 illustrated inFIG. 5D, adjacent magnet portions 654 of rotor portion 650X maygenerally have alternating polar orientations. Similarly, adjacentmagnet portions 654 of rotor portion 650Y may generally have alternatingpolar orientations. In other exemplary embodiments, however, alternateversions of rotor portion 650X may be utilized, for example wherein thepoles of adjacent magnet portions 654 within rotor 650X are alignedrather than alternating. Similar alternate versions of rotor portion650Y may be utilized. Moreover, all such combinations of alternatingand/or aligned magnets are considered to be within the scope of thepresent disclosure.

In various exemplary embodiments, polyphase device 600 may be operatedto generate electrical output from mechanical input. In other exemplaryembodiments, polyphase device 600 may be operated in a substantiallyreverse manner, wherein electrical input is supplied to one or morecoils in order to create mechanical output and/or other output (forexample, turning of one or more rotors and/or mechanical componentsattached thereto). It will be appreciated by one of ordinary skill inthe art that various principles may be applied to either and/or both ofthese configurations, as suitable.

In an exemplary embodiment, in order to generate electrical output frommechanical input, rotor portions 650X, 650Y spin relative to fluxconducting portions 612A along the direction D1 shown in FIG. 6B. Thiscauses magnet portions 654 and flux concentrators 652 of rotor portions650X, 650Y to alternately align with flux conducting portions 612A. Inthis manner, flux is conducted along the flux conducting portions 612A.

In an exemplary embodiment, orientation of successive magnet poles ofeach of magnet portions 654 is such that each flux conducting portion652 is at least partially surrounded by the same polarity of an abuttingpair of magnet portions 654. This orientation creates a flux path from afirst flux concentrator 652, through a flux conductor 612A, to a secondflux concentrator 652 different from the first flux concentrator 652. Inpolyphase device 600 these flux paths encircle sections of coils 620Asurrounded by flux conducting portions 612A. Rotating rotor portions650X, 650Y successively moves flux concentrators 652 having opposingpolarities near the flux conducting portions 612A. Thereby, rotatingrotor portions 650X, 650Y substantially reverses the direction of theflux path with each sequential passing of flux concentrators 652 andflux conducting portions 612A relative to one another. This processcreates alternating electrical output in coils 620A. Similar behaviorand results may be simultaneously obtained in each of flux conductingportions 612B and 612C, and coils 620B and 620C.

In various exemplary embodiments, inter-coil flux conductor spacingsSA-B, SB-C, and SC-A are different than intra-coil flux conductorspacings S610A, S610B, and S610C. In these embodiments, magnet portions654 and flux concentrators 652 of rotors 650X, 650Y are aligned withflux conducting portions 612 of different stator sections 610 atdifferent times. As a result, maximum flux conductance along a fluxconducting portion 612A occurs at a different time than for a fluxconducting portion 612B, and so on. The timing is governed by inter-coilflux conductor spacings SA-B, SB-C, and SC-A. In this manner, inter-coreflux conductor spacings SA-B, SB-C, and SC-A may create a phase lag inthe electrical output generated in a particular coil 620, for examplecoil 620A, with respect to the electrical output generated in one ormore of the other coils 620, for example coil 620B.

In an exemplary embodiment, with continued reference to FIG. 6C,inter-core flux conductor spacing SA-B is configured to create a 90°phase lag between the outputs of coils 620A and 620B. As illustrated,the inter-core flux conductor spacing SA-B is such that flux conductingportions 612A surrounding coil 620A are aligned with the fluxconcentrators 654 of rotor portions 650X, 650Y. At the same time, fluxconducting portions 612B surrounding coil 620B are aligned with magnetportions 654 of rotor portions 650X, 650Y. In this position, coils 620Aand 620B are about 90° out of phase with one another. Consequently, whenthere is maximum flux conductance in flux conducting portions 612Aaround coil 620A, minimum flux conductance occurs in flux conductingportions 612B around coil 620B, and vice versa. As can be appreciated,the reverse is also true. In this manner, an approximately 90° phase lagmay be created between the electrical outputs generated in coils 620Aand 620B by turning rotors 650X, 650Y.

FIG. 6C illustrates an inter-coil flux conductor spacing creating a 90°phase lag between adjacent coils. However, in various exemplaryembodiments, any suitable phase relationship between adjacent coils maybe obtained by adjusting the inter-coil flux conductor spacing. Forexample, a 180° phase lag between the output of adjacent coils 620A and620B can be created. This can be achieved by adjusting inter-coil fluxconductor spacing SA-B. Adjusting SA-B can cause flux conductingportions 612A surrounding coil 620A to align with flux concentrators 652having a first polarity at a given time T. Adjusting SA-B can also causeflux conducting portions 612B surrounding a coil 620B to align, at aboutthe same time T, with flux concentrators 652 having an oppositepolarity. Such an orientation result in, at any given time, flux beingconducted around adjacent coils 620A and 620B in opposing directions(e.g., flux is conducted in a generally clockwise direction around coil620A, while at the same time flux is conducted in a generallycounter-clockwise direction around coil 620B).

Similarly, adjusting SA-B can cause flux conducting portions 612Asurrounding coil 620A to align with flux concentrators 652 having afirst polarity at a given time T. Adjusting SA-B can also cause fluxconducting portions 612B surrounding a coil 620B to align, at about thesame time T, with flux concentrators 652 having the same polarity. Inthese configurations, coils 620A and 620B are substantially in phase.Moreover, in various exemplary embodiments, any suitable phaserelationship between coils 620, for example coils 620A and 620B, may beachieved by configuring an inter-coil flux conductor spacing, forexample SA-B.

Although exemplary relationships are shown and discussed for a phase lagbetween coils 620A and 620B, similar approaches apply to phaserelationships between any coils within polyphase device 600. Statedanother way, in various exemplary embodiments phase relationshipsbetween coils 620A, 620B, and 620C can be adjusted, varied, and/orotherwise modified and/or controlled by similarly adjusting one or moreof inter-coil flux conductor spacings SA-B, SB-C, and/or SC-A asdiscussed above. Further, these inter-coil flux conductor spacings canbe adjusted independently of one another. In this manner, any suitablenumber of phase relationships between coils 620A, 620B, and/or 620C ofpolyphase device 600 may be created.

Moreover, although FIGS. 6A-6C illustrate a polyphase device 600 whereinphase relationships are fixed once the stator is constructed, in otherexemplary embodiment polyphase devices may be configured with adjustablephase relationships between adjacent coils. For example, flux conductingportions 612A may be moveable with respect to flux conducting portions612B. All such polyphase devices having adjustable phase relationshipsare considered to be within the scope of the present disclosure.

In various exemplary embodiments, with reference again to FIGS. 6B and6C, flux conducting portions 612 associated with a particular coil 620may be interleaved and/or otherwise placed and/or arranged in analternating manner. For example, one flux conducting portion 612Apartially encloses forward portion 620AF. Moving along direction D1, thenext flux conducting portion 612A partially encloses rear portion 620AR.Continuing along direction D1, the next flux conducting portion 612Apartially encloses forward portion 620AF, and so on in an alternatingfashion. In this manner, flux conducting portions 612A may be placedmore compactly and/or tightly. In various exemplary embodiments, fluxconducting portions 612A may be arranged in an interleaved “back toback” configuration. In these arrangements, the “backs” of fluxconducting portions 612A may extend at least partially past one another,for example as illustrated in FIG. 6C. In this manner, polyphase device600 may be made more compact than if flux conducting portions 612A didnot extend at least partially past one another. However, flux conductingportions 612A may also be arranged in an alternating “back to back”configuration where portions of adjacent flux conducting portions 612Ado not extend past one another.

Similarly to the configurations discussed for flux conducting portions612A above, flux conducting portions 612B, 612C, and/or other fluxconducting portions of polyphase device 600 may be interleaved,interspersed, and/or otherwise alternated in a similar manner.

In addition to polyphase devices having an interior stator, principlesof the present disclosure contemplate polyphase devices having aninterior rotor. As used herein, an “interior rotor” refers to a rotorhaving a portion thereof and/or various components thereof disposedsubstantially between two or more stators. For example, in an exemplaryembodiment, and with reference now to FIGS. 7A-7C, a polyphase device700 is configured with an interior rotor 750. Polyphase device 700further comprises three stators each comprising a plurality of fluxconducting portions 712 (shown as 712A, 712B, and 712C). Polyphasedevice 700 further comprises three coils 720A, 720B, and 720C, locatedsubstantially within and/or surrounded by flux conducting portions 712A,712B, and 712C, respectively. Rotor 750 is also located substantiallywithin and/or surrounded by flux conducting portions 712A, 712B, and712C.

In various exemplary embodiments, the arrangement of flux conductingportions 712A, 712B, and 712C within polyphase device 700 issubstantially the inverse of the arrangement of flux conducting portions612A, 612B, and 612C within polyphase device 600 (see, e.g., FIGS.6A-6C), in the sense that orientation of each of flux conductingportions 712A, 712B, and 712C is reversed when compared to theorientation of flux conducting portions 612A, 612B, and 612C. In thismanner, polyphase device 700 is configured to operate with a singlerotor 750.

Polyphase device 700 may comprise multiple coils 720, for example coils720A, 720B, and 720C. Coils 720A, 720B, and 720C may correspond to oneor more output phases. In an exemplary embodiment, each coil 720A, 720B,and 720C corresponds to a different output phase. Any suitable number ofcoils 720 may be utilized. For example, three coils 720A, 720B, and 720Cmay be utilized, corresponding to three phase portions of polyphasedevice 700. Alternatively, two, four or more coils 720 may be used and,correspondingly, two, four or more stators. As can be appreciated, thenumber of phases within polyphase device 700 may range between one phaseto a number of phases equal to the number of coils 720 present inpolyphase device 700. In various exemplary embodiments, the spacingamong flux conducting portions 712A, 712B, and 712C associated withcoils 720A, 720B, and 720C, respectively, may be altered to create oneor more phase relationships between them.

In various exemplary embodiments, functional relationships betweenvarious components of polyphase device 700, for example between coils720A, 720B, and 720C and flux conducting portions 712A, 712B, and 712C,are substantially similar to relationships found in polyphase device600. Additionally, sizes, shapes, geometries, and/or othercharacteristics of components of polyphase device 700 may be similar tothose found in polyphase device 600. Moreover, the intra-coil spacingand inter-coil spacing of polyphase device 700 may similarly be variedto achieve multiple phases and/or phase relationships as disclosedhereinabove.

In contrast to the configuration of polyphase device 600, with furtherreference to FIG. 7C, in various exemplary embodiments each of coils720A, 720B, and 720C of polyphase device 700 are configured with a“bridging” segment 722A, 722B, and 722C (722C not shown), respectively,at a junction between adjacent coils. In these embodiments, coil 720Afurther comprises bridging segment 722A. Similarly, coil 720B furthercomprises bridging segment 722B, and coil 720C further comprisesbridging segment 722C. Bridging segments 722A and 722B are located atjunction J1 between coils 720A and 720B. Bridging sections may beutilized in order to complete loops in coils, for example withoutoccupying space desired for mechanical operation of rotor 750. Bridgingsections may be placed over and/or under a rotor, as desired. In thismanner, a rotor may be rotated without contacting a bridging segment.

Moreover, a bridging segment may be placed through magnets and/or fluxconcentrators, as desired. In various exemplary embodiments, a coil maybe coupled to a group of magnets and flux concentrators, and bridgingsegments may pass therethrough. Flux switches at least partiallyenclosing the coil may then be rotated to generate output in the coil.

In various exemplary embodiments, polyphase device 700 may be operatedin a manner at least partially similar to polyphase device 600. Forexample, polyphase device 700 may be operated to generated electricaloutput by providing a mechanical input to rotor 750. Polyphase device700 may also be operated to generate mechanical output at rotor 750responsive to electrical input in one or more coils 720. Moreover,polyphase device 700 may be configured with fixed phase relationships,for example by fixing flux conducting portions 712A, 712B, and 712C withrespect to one another. Alternatively, polyphase device 700 may beconfigured with variable phase relationships, for example by allowingflux conducting portions 712A, 712B, and 712C to move relative to oneanother, as disclosed hereinabove.

In addition to polyphase devices having an interior rotor, principles ofthe present disclosure contemplate polyphase devices having “slim”designs. As used herein, “slim” refer generally to configurations thatreduce a dimension of a polyphase device, for example configurationswherein coil paths are substantially orthagonal to the axis A of thepolyphase device, configurations wherein multiple rotors share a commonrotational plane, and/or the like.

For example, in an exemplary embodiment and with reference now to FIG.8A, a polyphase device 800 is configured with a slim design. Polyphasedevice 800 comprises three stators each comprising a plurality of fluxconducting portions 812 (shown as 812A, 812B, and 812C). Polyphasedevice 800 further comprises three coils 820A, 820B, and 820C. The pathsdefined by coils 820A, 820B, and 820C are generally orthagonal with theaxis A of rotation of polyphase device 800 (shown coming out of the pageas viewed in FIG. 8A). Polyphase device 800 further comprises one ormore rotor portions 850 (not shown).

In an exemplary embodiment, coils 820A, 820B, and 820C correspond tothree phases based on intra-coil flux conductor spacing and inter-coilflux conductor spacing as previously discussed. In other exemplaryembodiments, coils 820A, 820B, and 820C correspond to two phases and/orone phase. Moreover, because the plane defined by coils 820A, 820B, 820Cis substantially orthagonal to the axis A of polyphase device 800,polyphase device 800 may accordingly be formed to have a reduced or“slimmer” length along axis A. For example, polyphase device 800 may beformed to have a slimmer length along axis A than another design whereina coil path is not orthogonal to axis A, but is rather substantiallyparallel to and/or at least partially traverses a distance parallel toaxis A. Moreover, polyphase device 800 may slimmer than other designshaving multiple rotors located at different points along axis A. Statedanother way, in an exemplary embodiment, a first portion of a coil is inthe same rotational plane as a second portion of that coil. In general,polyphase device 800 may be sized, shaped, and/or otherwise configuredfor use in various applications where a particular length along arotational axis is desirable.

In various exemplary embodiments, with continued reference to FIG. 8C,each of the coils 820A, 820B, and 820C of polyphase device 800 comprisesa loop with an inner portion, 820AI, 820BI, 820CI, and a outer portion,820AO, 820BO, 820CO, respectively.

Moreover, outer portion 820AO may define a first arc, for example afirst semicircular arc. Inner portion 820AI may define a second arc, forexample a second semicircular arc. The first and second arcs areconcentric about a common axis, for example a rotational axis of atransverse flux machine and/or commutated flux machine. The first andsecond arcs may also be co-planar.

In various exemplary embodiments, outer portions 820AO, 820BO, and 820COextend along a portion of a circumference of a circle. Outer portions820AO, 820BO, and 820CO may extend any suitable portion of acircumference of a circle, for example approximately one-third of thecircumference. Outer portions 820AO, 820BO, and 820CO may extend alongportions having similar length. Moreover, outer portions 820AO, 820BO,and 820CO may extend along portions having dissimilar lengths, asdesired. Inner portions 820AI, 820BI, and 820CI may traverse angulardistances approximately corresponding to angular distances traversed byouter portions 820AO, 820BO, and 820CO, respectively, for exampleidentical angular distances. Alternatively, inner portions 820AI, 820BI,and 820CI may traverse different angular distances.

In various exemplary embodiments, functional relationships betweenvarious components of polyphase device 800, for example between coils820A, 820B, and 820C and flux conducting portions 812A, 812B, and 812C,are substantially similar to relationships found in polyphase device600. Additionally, sizes, shapes, geometries, and/or othercharacteristics of components of polyphase device 800 may be similar tothose found in polyphase device 600. Moreover, an intra-coil fluxconductor spacing and/or inter-coil flux conductor spacing of polyphasedevice 800 may similarly be varied to achieve multiple phases and/orphase relationships as disclosed hereinabove.

In various exemplary embodiments, polyphase device 800 may be operatedin a manner at least partially similar to polyphase device 600. Forexample, polyphase device 800 may be operated to generated electricaloutput by providing a mechanical input to a rotor. Polyphase device 800may also be operated to generate mechanical output at a rotor responsiveto electrical input in one or more coils 820. Moreover, polyphase device800 may be configured with fixed phase relationships, for example byfixing flux conducting portions 812A, 812B, and 812C with respect to oneanother. Alternatively, polyphase device 800 may be configured withvariable phase relationships, for example by allowing flux conductingportions 812A, 812B, and 812C to move relative to one another, asdisclosed hereinabove.

Further, in various exemplary embodiments, and with reference now toFIG. 8B, polyphase device 800 may be configured to reduce the amount ofcoil material at a junction between adjacent coils. In an exemplaryembodiment, one or more bridging sections 822A, 822B, and 822C 822Bcomplete coils 820A, 820B, and 820C, respectively. For example, bridgingsections 822A and 822B complete coils 820A and 820B at junction J2.Bridging sections 822A, 822B, and 822C may be significantly thinner thancorresponding bridging sections 722A, 722B, and 722C for polyphasedevice 700. For example, in an exemplary embodiment bridging sections822A, 822B, and 822C are thinner in a “slim” configuration becausebridging sections 822A, 822B, and 822C may not need to extend out of theplane of the main body of coils 820A, 820B, and 820C, respectively, forexample in order to allow clearance for a rotor. In this manner, theamount of material utilized in coils 820A, 820B, and 820C may bedesirably reduced. Because materials comprising coils 820A, 820B, and820C are often heavy and/or expensive, and because materials comprisingcoils 820A, 820B, and 820C are prone to resistive heating and/or otherlosses, reducing the amount of material in coils 820A, 820B, and 820Cmay be advantageous. Moreover, because coil material comprising bridgingsections 822A, 822B, and 822C is not at least partially surrounded by acorresponding flux conducting portion 812A, 812B, or 812C, this materialis generally not generating useful output, but rather losses. Hence,this material may be considered to be somewhat similar to material in an“end turn” in a conventional motor, and as such may be suitably reducedand/or minimized, as desired.

In various exemplary embodiments, although no rotors are illustrated inFIGS. 8A and 8B, polyphase device 800 may accommodate a suitable numberof rotors, for example two rotors, in order to allow interaction betweenthe rotors and various portions of polyphase device 800. Moreover,polyphase device 800 may comprise any suitable number of rotors, asdesired.

In addition to polyphase devices having slim designs, principles of thepresent disclosure contemplate polyphase devices wherein a firstpolyphase device is “nested” within another polyphase device, forexample about a common axis. As used herein, a “nested” configurationrefers to a single-phase and/or polyphase device surrounding anothersingle-phase and/or polyphase device having a common axis. By utilizinga nesting configuration, the resulting combined polyphase device may beconfigured with an increased mechanical and/or electrical outputpotential for a particular device size.

For example, multiple nested polyphase devices may be connected to thesame mechanical device, such as the drive shaft for a vehicle. In thisway, in various exemplary embodiments a combined polyphase device canprovide many times, for example three times, the output of an un-nestedpolyphase device, with essentially the same footprint. Theseconfigurations can be particularly advantageous for applicationsrequiring a higher power output in a relatively compact and/or fixedspace, for example motors for electric vehicles or other electricmotors. Nested polyphase devices can also be used, for example, toderive a greater amount of electrical output from a similar amount ofmechanical input. Such an approach enables more compact electricalgenerator designs, turbine designs, and/or designs for devicesincorporating the same.

Moreover, although various exemplary nested devices discussed herein arepolyphase devices, it will be appreciated by one skilled in the art thatvarious single-phase devices, for example devices presented in variousco-pending applications incorporated by reference herein, may beconfigured in a nested arrangement. Principles of the present disclosuremay apply equally to such configurations, and all such applications,configurations, and/or nesting arrangements are considered to be withinthe scope of the present disclosure.

Turning now to FIG. 9A, in an exemplary embodiment a nested polyphasedevice 900 comprises a first polyphase device 900A and a secondpolyphase device 900B. Second polyphase device 900B may be substantiallysimilar to first polyphase device 900A. For example, second polyphasedevice 900B may be a scaled-down or smaller version of first polyphasedevice 900A. Alternatively, second polyphase device 900B may beconfigured with a design substantially different from first polyphasedevice 900A. Second polyphase device 900B is configured to be located atleast partially within first polyphase device 900A.

In an exemplary embodiment, configuring second polyphase device 900B tobe a scaled-down or smaller version of first polyphase device 900A isuseful in order to preserve phase relationships between first polyphasedevice 900A and second polyphase device 900B. In other exemplaryembodiments, phase relationships between first polyphase device 900A andsecond polyphase device 900B may be maintained, varied, and/orcontrolled by utilizing similarly sized components therein, bututilizing different stator component spacing, different rotorconfigurations, and/or the like.

In various exemplary embodiments, certain components of second polyphasedevice 900B and/or other components and/or features of polyphase device900 are scaled down in size from similar components in first polyphasedevice 900A, for example by an approximately consistent scaling factor.For example, in an exemplary embodiment flux conducting portions 912B ofsecond polyphase device 900B are approximately half the size of fluxconducting portions 912A of first polyphase device 900A.Correspondingly, a spacing between adjacent flux conducting portions912B on second polyphase device 900B may be approximately half that of aspacing between adjacent flux conducting portions 912A on firstpolyphase device 900A. Moreover, in order to maintain a desired phaserelationship, a rotor utilized in second polyphase device 900B may be ascaled down version of a rotor utilized in first polyphase device 900A,for example a rotor scaled down by a similar factor. Thus, for example,magnet portions and flux concentrating portions of a rotor for secondpolyphase device 900B may be approximately half the size of magnetportions and flux concentrating portions of a rotor for first polyphasedevice 900A.

In various exemplary embodiments, a rotor for second polyphase device900B is connected to the same mechanical input/output device as a rotorfor first polyphase device 900A so as to operate in tandem. Thisarrangement can be advantageous, for example in applications withspatial restrictions. Moreover, these rotors may also be coupled todifferent mechanical devices, such that first polyphase device 900A andsecond polyphase device 900B may be utilized substantiallyindependently.

Moreover, polyphase device 900 may comprise any suitable number ofnested polyphase devices. In principle, an area comprising an interiorsection of a particular polyphase device may be substantially filledwith one or more additional polyphase and/or single-phase devices inorder to form polyphase device 900.

In various exemplary embodiments, a physical alignment may exist betweenlike phase portions of a first polyphase device 900A and a secondpolyphase device 900B (see, e.g., FIG. 9A). In these embodiments, a coil920A of first polyphase device 900A and a corresponding coil 920B ofsecond polyphase device 900B are configured to correspond toapproximately a same input/output phase. Moreover, corresponding coils(e.g., 920A and 920B) may be electrically connected so as to providesimilar output or to receive a similar input. Alternatively,corresponding coils may be connected in other arrangements more suitedfor a particular implementation.

Additionally, polyphase device 900 may comprise a phase-staggeredconfiguration. With reference now to FIG. 9B, in various exemplaryembodiments polyphase device 900 comprises a first polyphase device 900Aand a second, similar polyphase device 900B nested therein in aphase-staggered configuration. In these exemplary embodiments, similarphase portions of first polyphase device 900A and second polyphasedevice 900B, for example coils 920A and 920B, are staggered in order toincrease a distance therebetween. In this manner, electricalinterference between similar phase portions may be reduced. Moreover,interference between coils at junctions J2, J3 and J4 in first polyphasedevice 900A, and between coils at junctions J5, J6 and J7 in secondpolyphase device 900B may similarly be reduced. Additionally, phasestaggering may reduce noise, vibration, and/or the like, for example bya mechanical pulse generated in one portion of the device correspondingto a similar mechanical pulse generated at approximately the same timeon an opposite side.

In various exemplary embodiments, portions of first polyphase device900A corresponding to approximately the same input/output phase asportions of second polyphase device 900B may be located on generallyopposite sides of polyphase device 900. For example, in an exemplaryembodiment, coils 920A and 920B correspond to approximately the sameoutput phase. Coils 920A and 920B may be located approximately 180rotational degrees away from one another about an axis of rotation ofpolyphase device 900. Stated another way, coils 920A and 920B may belocated on generally opposite sides of polyphase device 900. In thismanner, physical separation between corresponding phases may bemaximized.

Moreover, various alternate configurations of any of the polyphasedevices disclosed herein are within the scope of the present disclosure.For example, FIGS. 5A-5C illustrate axial gap configurations. Certainexemplary embodiments, including but not limited to those depictedtherein, may alternatively be configured with radial gap configurations,as desired. In contrast, FIGS. 6A-6C, 7A-7C, 8A-8C, 9A-9B, and 10illustrate radial gap configurations. Other exemplary embodiments,including but not limited to those depicted therein, may alternativelybe configured with axial gap configurations, as desired.

Furthermore, FIGS. 5A-5B, 6A-6C, 7A-7C, 8A-8C, 9A-9B, and 10 illustratecavity engaged configurations. Various exemplary embodiments, includingbut not limited to those depicted therein, may alternatively beconfigured with face engaged configurations, as desired. In contrast,FIG. 5C illustrates a face engaged configuration. Various otherexemplary embodiments, including but not limited to those depictedtherein, may also be configured with cavity engaged configurations, asdesired.

Moreover, FIGS. 5A-10 illustrate transverse flux machine configurations.Various exemplary embodiments, including but not limited to thosedepicted therein, may alternatively be configured with commutated fluxmachine configurations.

For example, in various exemplary embodiments, a polyphase device mayutilize a plurality of partial stators sharing a common rotor, forexample a multipath rotor. In an exemplary embodiment, a polyphasedevice may comprise three partial stators sharing a common rotor, eachpartial stator corresponding to an input and/or output phase. Moreover,a polyphase device may comprise any suitable number of partial stators,as desired. Use of one or more partial stators may facilitate assemblyand/or disassembly of a polyphase device.

Use of one or more partial stators may also facilitate scalable and/ormodular polyphase devices, wherein partial stators may be added and/orremoved, as desired. A partial stator may be added and/or removed inorder to modify one or more properties of a polyphase device, forexample a torque density, a power output, an input and/or outputelectrical waveform, and/or the like.

In various exemplary embodiments and in accordance with principles ofthe present disclosure, a polyphase device may be configured for use ina vehicle. For example, with momentary reference to FIG. 10, a polyphasedevice 1000 may be mounted on an axle of a wheel. In this manner,polyphase device 1000 may function as a direct drive hub motor.

In an exemplary embodiment, polyphase device 1000 may be similar topolyphase device 700 having an interior rotor. For example, polyphasedevice 1000 comprises at least two coils 1020A and 1020B, and a rotor1050 disposed between portions of each of coils 1020A and 1020B.However, any suitable polyphase device may be utilized in a vehicle, andthe exemplary embodiments presented herein are by way of illustrationand not of limitation.

Principles of the present disclosure may suitably be combined withprinciples for stators in transverse flux machines and commutated fluxmachines, for example principles for partial stators and/or gappedstators, as disclosed in U.S. patent application Ser. No. 12/611,728filed Nov. 3, 2009, now U.S. Pat. No. 7,851,965 entitled “TRANSVERSEAND/OR COMMUTATED FLUX SYSTEM STATOR CONCEPTS”, the contents of whichare hereby incorporated by reference in their entirety.

Principles of the present disclosure may also suitably be combined withprinciples for rotors in transverse flux machines and commutated fluxmachines, for example tape wound rotors and/or multipath rotors, asdisclosed in U.S. patent application Ser. No. 12/611,733 filed Nov. 3,2009, now U.S. Pat. No. 7,923,886 entitled “TRANSVERSE AND/OR COMMUTATEDFLUX SYSTEM ROTOR CONCEPTS”, the contents of which are herebyincorporated by reference in their entirety.

Moreover, principles of the present disclosure may suitably be combinedwith any number of principles disclosed in any one of and/or all of theU.S. Patent Applications incorporated by reference herein. Thus, forexample, a particular transverse flux machine and/or commutated fluxmachine may incorporate use of a tape wound rotor, use of a multipathrotor, use of a partial stator, use of a polyphase design, and/or thelike. All such combinations, permutations, and/or otherinterrelationships are considered to be within the scope of the presentdisclosure.

While the principles of this disclosure have been shown in variousembodiments, many modifications of structure, arrangements, proportions,the elements, materials and components, used in practice, which areparticularly adapted for a specific environment and operatingrequirements may be used without departing from the principles and scopeof this disclosure. These and other changes or modifications areintended to be included within the scope of the present disclosure andmay be expressed in the following claims.

In the foregoing specification, the invention has been described withreference to various embodiments. However, one of ordinary skill in theart appreciates that various modifications and changes can be madewithout departing from the scope of the present disclosure. Accordingly,the specification is to be regarded in an illustrative rather than arestrictive sense, and all such modifications are intended to beincluded within the scope of the present disclosure. Likewise, benefits,other advantages, and solutions to problems have been described abovewith regard to various embodiments. However, benefits, advantages,solutions to problems, and any element(s) that may cause any benefit,advantage, or solution to occur or become more pronounced are not to beconstrued as a critical, required, or essential feature or element ofany or all the claims. As used herein, the terms “comprises,”“comprising,” or any other variation thereof, are intended to cover anon-exclusive inclusion, such that a process, method, article, orapparatus that comprises a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus. Also, as used herein,the terms “coupled,” “coupling,” or any other variation thereof, areintended to cover a physical connection, an electrical connection, amagnetic connection, an optical connection, a communicative connection,a functional connection, and/or any other connection. When languagesimilar to “at least one of A, B, or C” is used in the claims, thephrase is intended to mean any of the following: (1) at least one of A;(2) at least one of B; (3) at least one of C; (4) at least one of A andat least one of B; (5) at least one of B and at least one of C; (6) atleast one of A and at least one of C; or (7) at least one of A, at leastone of B, and at least one of C.

Statements of Invention

An electrical machine, comprising: a conductive coil comprising a firstcoil portion, a second coil portion, a first coil end, and a second coilend, wherein the first coil portion and the second coil portion areconnected via the first coil end and the second coil end to form a loop,wherein a voltage is induced in more than 90% of the coil mass, andwherein the electrical machine is at least one of a transverse fluxmachine or a commutated flux machine.

An electrical machine, comprising: a first rotor having a first plane ofrotation; a second rotor having a second plane of rotation parallel toand non-overlapping the first plane of rotation, wherein the first rotorand second rotor have a common rotational axis; and a stator at leastpartially enclosing a coil, wherein the stator is located substantiallybetween the first rotor and the second rotor, wherein the stator engagesthe first rotor and the second rotor, and wherein the electrical machineis at least one of a transverse flux machine or a commutated fluxmachine.

An electrical machine, comprising: a conductive coil comprising a firstcoil portion, a second coil portion, a first coil end, and a second coilend, wherein the first coil portion and the second coil portion areconnected via the first coil end and the second coil end to form a loop;a first set of flux conductors at least partially enclosing the firstcoil portion, wherein the first set of flux conductors engage a firstrotor; and a second set of flux conductors at least partially enclosingthe second coil portion, wherein the second set of flux conductorsengage a second rotor, wherein the first set and the second set arearranged back-to-back, and wherein the electrical machine is at leastone of a transverse flux machine or a commutated flux machine. The firstset and the second set are arranged in an alternating manner.

An electrical machine, comprising: a conductive coil comprising a firstcoil portion, a second coil portion, a first coil end, and a second coilend, wherein the first coil portion and the second coil portion areconnected via the first coil end and the second coil end to form a loop;and a rotor, wherein the first coil portion is located on a first sideof the rotor, wherein the second coil portion is located on an oppositeside of the rotor, wherein the first coil end and the second coil endextend from the first side of the rotor to the opposite side of therotor to form the loop, and wherein the electrical machine is at leastone of a transverse flux machine or a commutated flux machine. The firstcoil end may comprise a bridging segment traversing the rotor such thatthe rotor is between the bridging segment and an axis of rotation. Thefirst coil end may comprise a bridging segment passing between the rotorand an axis of rotation. The electrical machine may be a polyphasemachine. The electrical machine may further comprise a first set of fluxconductors at least partially enclosing the first coil portion, whereinthe first set of flux conductors engage a first side of the rotor, and asecond set of flux conductors at least partially enclosing the secondcoil portion, wherein the second set of flux conductors engage a secondside of the rotor different from the first side, and wherein the firstside and the second side are separated by a rotational plane of therotor.

An electrical machine, comprising: a rotor having a first side and asecond side separated by a rotational plane of the rotor; a first set offlux conducting portions engaging the first side; a second set of fluxconducting portions engaging the second side; and a coil at leastpartially enclosed by the first set of flux conducting portions and thesecond set of flux conducting portions, wherein the electrical machineis at least one of a transverse flux machine or a commutated fluxmachine.

A nested electrical machine, comprising: a first electrical machine anda second electrical machine having a common rotational axis, wherein thesecond electrical machine is disposed entirely within an inner radius ofthe first electrical machine, wherein the first electrical machine is atleast one of a transverse flux machine or a commutated flux machine, andwherein the second electrical machine is at least one of a transverseflux machine or a commutated flux machine. The first electrical machineand the second electrical machine may differ in phase.

An electrical machine, comprising: a rotor; and a plurality of partialstators coupled to the rotor, wherein each partial stator of theplurality of partial stators corresponds to a different input/outputphase, and wherein the electrical machine is at least one of atransverse flux machine or a commutated flux machine.

An electrical machine, comprising: a first rotor having a first radius;a second rotor having a second radius smaller than the first radius, thefirst rotor and the second rotor having a common rotational plane; aconductive coil comprising a first coil portion, a second coil portion,a first coil end, and a second coil end, wherein the first coil portionand the second coil portion are connected via the first coil end and thesecond coil end to form a loop; wherein the first coil portion is atleast partially enclosed by a first set of flux conductors, wherein thesecond coil portion is at least partially enclosed by a second set offlux conductors, wherein the first set of flux conductors engage onlythe first rotor, and wherein the second set of flux conductors engageonly the second rotor.

1. An electrical machine, comprising: a stator comprising a set of fluxconductors; and a conductive coil extending only partway around theelectrical machine; wherein the set of flux conductors engage over 90%of the length of the conductive coil, and wherein the electrical machineis at least one of a transverse flux machine or a commutated fluxmachine.
 2. The electrical machine of claim 1, wherein the conductivecoil comprises a first coil portion, a second coil portion, a first coilend, and a second coil end, wherein the first coil portion and thesecond coil portion are connected via the first coil end and the secondcoil end to form a loop.
 3. The electrical machine of claim 1, whereinthe conductive coil is oriented in the electrical machine such that,responsive to rotation of a rotor of the electrical machine, current ina first portion of the conductive coil flows in a direction of rotationof the rotor simultaneously with current in a second portion of theconductive coil flowing opposite the direction of rotation of the rotor.4. The electrical machine of claim 1, further comprising a plurality ofconductive coils, each conductive coil extending only partway around theelectrical machine.
 5. The electrical machine of claim 1, wherein afirst portion of the set of flux conductors engage a first rotor of theelectrical machine, and wherein a second portion of the set of fluxconductors engage a second rotor of the electrical machine.
 6. Theelectrical machine of claim 5, wherein the first portion of the set offlux conductors are interleaved with the second portion of the set offlux conductors.
 7. The electrical machine of claim 1, wherein theelectrical machine is configured with a continuous, thermally stabletorque density in excess of 50 Newton-meters per kilogram.
 8. Theelectrical machine of claim 1, wherein the electrical machine isconfigured with a continuous, thermally stable torque density in excessof 100 Newton-meters per kilogram, and wherein the electrical machine isconfigured with a diameter of less than 20 inches.
 9. A hub motor for anelectric vehicle, the hub motor comprising: a stator comprising a set offlux conductors; and a conductive coil extending only partway around theelectrical machine; wherein the set of flux conductors engage over 90%of the length of the conductive coil, and wherein the hub motor is atleast one of a transverse flux machine or a commutated flux machine.13195365
 10. The hub motor of claim 9, wherein the conductive coilcomprises a first coil portion, a second coil portion, a first coil end,and a second coil end, wherein the first coil portion and the secondcoil portion are connected via the first coil end and the second coilend to form a loop.
 11. The hub motor of claim 9, further comprising arotor having an inner side and an outer side with respect to arotational axis of the hub motor, wherein the set of flux conductors areengaged with the inner side of the rotor in a face engagedconfiguration.
 12. A motor for an electric vehicle, the motorcomprising: a rotor having a first side and a second side separated by arotational plane of the rotor; a first set of flux conductors engagingthe first side; a second set of flux conductors engaging the secondside; and a conductive coil at least partially enclosed by the first setof flux conductors and the second set of flux conductors, wherein themotor is at least one of a transverse flux machine or a commutated fluxmachine.
 13. The motor of claim 12, wherein the conductive coilcomprises a first coil portion, a second coil portion, a first coil end,and a second coil end, wherein the first coil portion and the secondcoil portion are connected via the first coil end and the second coilend to form a loop.
 14. The motor of claim 12, wherein the conductivecoil extends only partway around the electrical machine.
 15. The motorof claim 14, wherein the first set of flux conductors at least partiallyenclose a first portion of the conductive coil disposed on the firstside, and wherein the second set of flux conductors at least partiallyenclose a second portion of the conductive coil disposed on the secondside.
 16. The motor of claim 12, wherein the motor is a polyphasedevice.
 17. The motor of claim 12, wherein the motor is coupled to thehub of the electric vehicle in a direct drive configuration.
 18. Amethod of propelling a vehicle, comprising: coupling an electricalmachine to a hub of a vehicle in a direct drive configuration; andenergizing a conductive coil of the electrical machine to impart arotational force to the hub, wherein the electrical machine is at leastone of a transverse flux machine or a commutated flux machine.
 19. Themethod of claim 18, wherein the electrical machine comprises: a rotorhaving a first side and a second side separated by a rotational plane ofthe rotor; a first set of flux conductors engaging the first side; asecond set of flux conductors engaging the second side; and a conductivecoil at least partially enclosed by the first set of flux conductors andthe second set of flux conductors.
 20. The method of claim 18, whereinthe electrical machine comprises: a rotor having an inner side and anouter side with respect to a rotational axis of the electrical machine;and a set of flux conductors at least partially enclosing the conductivecoil, wherein the set of flux conductors are engaged with the inner sideof the rotor in a face engaged configuration.
 21. The method of claim18, wherein the conductive coil extends only partway around theelectrical machine.
 22. The method of claim 18, wherein the electricalmachine is configured with a continuous, thermally stable torque densityin excess of 100 Newton-meters per kilogram, and wherein the electricalmachine is configured with a diameter of less than 20 inches.
 23. Themethod of claim 18, further comprising transferring rotational forcefrom the hub to induce a voltage in the conductive coil.